AIR CONDITIONING SYSTEM PRECAUTION

Transcription

1 SYSTEM SYSTEM PRECAUTION AC1 AC15I04 1. DO NOT HANDLE REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME 2. ALWAYS WEAR EYE PROTECTION AC2810 AC BE CAREFUL NOT TO GET LIQUID REFRIGERANT IN YOUR EYES OR ON YOUR SKIN If liquid refrigerant gets in your eyes or on your skin. (a) Wash the area with lots of cool water. CAUTION: Do not rub your eyes or skin. (b) Apply clean petroleum jelly to the skin. (c) Go immediately to a physician or hospital for professional treatment. 4. NEVER HEAT CONTAINER OR EXPOSE IT TO NAKED FLAME 5. BE CAREFUL NOT TO DROP CONTAINER AND NOT TO APPLY PHYSICAL SHOCKS TO IT Wrong LO HI Okay LO HI N DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM If there is not enough refrigerant in the refrigerant system oil lubrication will be insufficient and compressor burnout may occur, so take care to avoid this, necessary care should be taken. 7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING If the high pressure valves opened, refrigerant flows in the reverse direction and could cause the charging cylinder to rupture, so open and close the only low pressure valve. 8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine overheating etc. 2467

2 AC2 SYSTEM 9. SUPPLEMENTAL RESTRAINT SYSTEM (SRS) The LEXUS IS300 is equipped with an SRS (Supplemental Restraint System) such as the driver, passenger and side airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing, possibly leading to a serious accident. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the precautionary notices in the RS section. 2468

3 AC10 Quick Disconnect Adapter Charging Hose Service Valve N13795 EVACUATING SYSTEM AC15K05 1. CONNECT QUICK DISCONNECT ADAPTER TO CHARGING HOSES 2. REMOVE CAPS FROM SERVICE VALVES ON RE FRIGERANT LINES 3. SET ON MANIFOLD GAUGE SET (a) Close both hand valves of manifold gauge set. (b) Connect the quick disconnect adapters to the service valves. Vacuum Pump 4. EVACUATE AIR FROM REFRIGERATION SYSTEM (a) Connect the vacuum pump adapter to the vacuum pump. Vacuum Pump Adapter N13794 Manifold Gauge Set Low Pressure Service Valve (b) Connect the center hose of the manifold gauge set to the vacuum pump adapter. (c) Open both the high and low hand valves and run the vacuum pump. (d) After 10 minutes or more, check that the low pressure gauge indicates 750 mmhg (30 in. Hg) or more. HINT: If the reading is 750 mmhg (30 in. Hg) or more, close both hand valves of manifold gauge set and stop the vacuum pump. Check the system for leaks and repair if necessary. (e) Close both the high and low hand valves and stop the vacuum pump. (f) Leave the system in this condition for 5 minutes or more and check that there is no gauge indicator. High Pressure Service Valve Vacuum Pump Adapter N

4 Air Low Pressure Service Valve Push High Pressure Service Valve SYSTEM AC1 1 AC25K02 CHARGING 1. INSTALL CHARGING CYLINDER HINT: When handling the charging cylinder, always follow the directions given in the instruction manual. (a) Charge the proper amount of refrigerant into the charging cylinder. (b) Connect the center hose to the charging cylinder. CAUTION: Do not open both high and low hand valves of manifold gauge set. (c) Open the valve of charging cylinder. (d) Press the valve core on the side of manifold gauge and expel the air inside of the center hose. Charging Cylinder N INSPECT REFRIGERATION SYSTEM FOR LEAKS (a) Open the high pressure hand valve and charge refrigerant. (b) When the low pressure gauge indicates 98 kpa (1 kgf/cm 2, 14 psi) close the high pressure hand valve. (c) Using a gas leak detector, check the system for leakage. If leak is found, repair the faulty component or connection. CAUTION: Use the refrigerant recovery/ recycling machine to recover the refrigerant whenever replacing parts. Gas Leak Detector N

5 AC12 SYSTEM Low Pressure Service Valve High Pressure Service Valve N CHARGE REFRIGERANT INTO REFRIGERATION SYSTEM If there is no leak after refrigerant leak check charge, the proper amount of refrigerant in to refrigeration system. CAUTION: Never run the engine when charging the system through the high pressure side. Do not open the low pressure hand valve when the system is being charged with liquid refrigerant. (a) Open he high pressure hand valve fully. (b) Charge specified amount of refrigerant, then close the high pressure hand valve. HINT: A fully charged system is indicated by the sight glass being free of any bubbles. (c) Charge partially refrigeration system with refrigerant. (1) Set vehicle in these conditions: Running engine at 1,500 rpm Blower speed control set at HI Temperature control set at MAX. COOL position Air inlet control set at RECIRC Fully open doors (Sliding roof : closed) (2) Open the low pressure hand valve. CAUTION: Do not open the high pressure hand valve. Properly Charged (3) Charge refrigerant until bubbles disappear and check the pressure on the gauge through the sight glass. Insufficiently Charged I

6 SYSTEM AC13 LOCATION AC15M03 Condenser Fan Condenser Compressor Engine Room Relay Block No. 2 Cooling Fan Relay No. 3 Cooling Fan Relay Magnetic Clutch Relay Passenger Side Junction Block Heater Main Relay Water Temperature Switch Solar Sensor A/C Control Assembly Expansion Valve Evaporator Room Temperature Sensor Evaporator Temperature Sensor Air Outlet Servomotor Air Inlet Servomotor Heater Radiator Air Refiner Filter Air Mix Servomotor Blower Motor Control Relay Blower Motor I

7 AC14 TROUBLESHOOTING PROBLEM SYMPTOMS TABLE TROUBLESHOOTING Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order If necessary, replace these parts. Symptom Suspect Area See page AC20D03 Whole functions of A/C system do not operate No blower operation No blower control 1. A.C Fuse 2. A/C control assembly 1. Heater main relay 2. Blower motor 3. Blower motor control relay 4. A/C control assembly 5. Wire harness 1. Blower motor 2. Blower motor control relay 3. A/C control assembly 4. Wire harness AC79 AC69 AC55 AC56 AC79 AC55 AC56 AC79 Insufficient air out 1. Blower motor AC55 No cool air comes out No warm air comes out Out put air is warmer or cooler than the set temperature or response is slow No temperature control 1. Refrigerant volume 2. Drive belt 3. Refrigerant pressure 4. Compressor 5. Pressure switch 6. Igniter circuit 7. Air mix servomotor 8. Room temp. sensor 9. Ambient temp. sensor 10.A/C control assembly 11.Wire harness 1. Engine coolant volume 2. Air mix servomotor 3. Ambient temp. sensor 4. Room temp. sensor 5. A/C control assembly 6. Heater radiator 1. Refrigerant volume 2. Engine coolant volume 3. Drive belt 4. Refrigerant pressure 5. Condenser fan 6. Ambient temp. sensor 7. Evaporator temp. sensor 8. Solar sensor 9. Air mix servomotor 10.Compressor 11.Condenser 12.Evaporator 13.Heater radiator 14.Expansion valve 15.A/C control assembly 16.Wire harness 1. Air mix servomotor 2. A/C control assembly AC3 AC16 AC3 AC38 AC66 AC30 AC62 AC63 AC79 AC30 AC63 AC62 AC79 AC30 AC3 AC16 AC3 AC72 AC63 AC64 AC61 AC30 AC38 AC47 AC30 AC30 AC52 AC79 AC30 AC

8 TROUBLESHOOTING AC15 No air inlet control No mode control No engine idleup when A/C switch ON 1. Air inlet servomotor 2. A/C control assembly 3. Wire harness 1. Air outlet servomotor 2. A/C control assembly 3. Wire harness 1. A/C control assembly 2. Wire harness AC57 AC79 AC59 AC79 AC79 Set temperature value does not match up with operation of temperature control switch 1. A/C control assembly AC79 Brightness does not change when light control switch is turned 1. Headlight and taillight system 2. A/C control assembly BE31 AC

9 AC16 DRIVE BELT DRIVE BELT ONVEHICLE INSPECTION AC37T01 1. INSPECT DRIVE BELT S INSTALLATION CONDITION Check that the drive belt fits properly in the ribbed grooves. Correct Wrong CH0086 Type A A B Type B 2. INSPECT DRIVE BELT TENSION Check that the arrow mark on the belt tensioner falls within area A of the scale. If it is out side area A, replace the drive belt. HINT: When a new belt is installed, it should be lie within area B. A B P

10 SST DRIVE BELT AC17 AC17Z05 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE DRIVE BELT Using SST, loosen the drive belt tension by turning the drive belt tensioner arm clockwise from the bottom side, and remove the drive belt. SST I

11 AC18 DRIVE BELT INSTALLATION Installation is in the reverse order of removal (See page AC17 ). AFTER INSTALLATION, CHECK DRIVE BELT S INSTALLATION CONDITION AC37U

12 MANIFOLD GAUGE SET MANIFOLD GAUGE SET SET ON AC19 AC15Q04 1. CONNECT CHARGING HOSES TO MANIFOLD GAUGE SET Tighten the nuts by hand. CAUTION: Do not connect the wrong hoses. 2. CONNECT QUICK DISCONNECT ADAPTERS TO CHARGING HOSES Tighten the nuts by hand. 3. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET 4. REMOVE CAPS FROM SERVICE VALVE ON REFRIG ERANT LINES Low Pressure Charging Hose High Pressure Charging Hose I18041 Sleeve 5. CONNECT QUICK DISCONNECT ADAPTERS TO SER VICE VALVES HINT: Push the quick disconnect adapter onto the service valve, then slide the sleeve of the quick disconnect adapter downward to lock it. N

13 AC20 N06553 SET OFF MANIFOLD GAUGE SET AC15R04 1. CLOSE BOTH HAND VALVES OF MANIFOLD GAUGE SET 2. DISCONNECT QUICK DISCONNECT ADAPTERS FROM SERVICE VALVES ON REFRIGERANT LINE HINT: Slide the sleeve of the quick disconnect adapter upward to unlock the adapter and remove it from the service valve. 3. INSTALL CAPS TO SERVICE VALVES ON REFRIGER ANT LINES 2486

14 REFRIGERANT LINE REFRIGERANT LINE ONVEHICLE INSPECTION 1. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. AC21 AC15S

15 AC22 REFRIGERANT LINE COMPONENTS AC15T04 10 (100, 7) Condenser Liquid Tube 10 (100, 7) Suction Tube Compressor 10 (100, 7) Discharge Hose N m (kgf cm, ft lbf) : Specified amount I

16 REFRIGERANT LINE REPLACEMENT 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 2. REPLACE FAULTY TUBE OR HOSE NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. 3. TIGHTEN JOINT OF BOLT OR NUT TO SPECIFIED TORQUE NOTICE: Connections should not be torqued tighter than the specified torqued. AC23 AC15U02 Part tightened N m kgf cm ft lbf Compressor x Discharge hose Compressor x Suction hose Condenser x Discharge hose Condenser x Liquid tube A/C unit x Liquid and Suction tubes Suction line (Block joint) EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. 6. INSPECT OPERATION 2489

17 AC24 UNIT UNIT COMPONENTS AC37V01 Instrument Panel Reinforcement Defroster Nozzle Water Hose Liquid Tube 10 (100, 7) A/C Unit ORing Suction Tube Blower Unit Bracket Air Duct LH Air Duct RH Nonreusable part N m (kgf cm, ft lbf) : Specified torque I

18 UNIT AC25 Packing Wire Harness Expansion Valve Tube Connector Evaporator Temperature Sensor Bracket Plate Packing Tube and Accessory ORing ORing Packing Wire Harness ORing Evaporator Air Duct (Duct Side) 4.1 (42, 36 in. lbf) Air Duct (Duct Side) Air Duct (Unit Side) Air Duct (Unit Side) Plate Drain Hose Air Outlet Servomotor Drain Hose Air Mix Servomotor Insulator Cover Pipe Clamp Heater Radiator Blower Motor Control Relay N m (kgf cm, ft lbf) :Specified torque Nonreusable part I

19 AC26 REMOVAL UNIT AC15W03 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 2. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all coolant. I DISCONNECT LIQUID TUBE AND SUCTION HOSE FROM A/C UNIT Remove the bolt and slide the plate, then disconnect the both tubes. Torque: 10 N m (100 kgf cm, 7 ft lbf) NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 2 new Orings with compressor oil and install them to the tubes. 4. DISCONNECT WATER HOSES FROM HEATER RA DIATOR PIPES (a) Grip the claws of the hose clip and slide the hose clip along the hose. (b) Disconnect the water hose. I

20 UNIT AC27 5. REMOVE COOLER NO. 1 GROMMET 6. REMOVE HEATER PIPE GROMMET 7. REMOVE DRAIN HOSE GROMMET 8. REMOVE INSTRUMENT PANEL AND REINFORCE MENT (See page BO139 ) 9. REMOVE BLOWER UNIT (See page AC34 ) 10. REMOVE 2 AIR DUCTS (a) Slide the floor carpet backward. (b) Remove the air ducts LH, RH. I REMOVE A/C UNIT (a) Disconnect the connectors. (b) Disconnect the wire harness clamps. (c) Remove the 2 nuts, 2 bolt and A/C unit. I

21 AC28 UNIT DISASSEMBLY 1. REMOVE WIRE HARNESS 2. REMOVE DRAIN HOSE AC37W01 I REMOVE HEATER RADIATOR (a) Remove the screw and clamp. (b) Pull out the heater radiator. 4. REMOVE BLOWER MOTOR CONTROL RELAY Remove the screw and blower motor control relay. 5. REMOVE AIR MIX SERVOMOTOR Remove the 3 screws and servomotor. 6. REMOVE AIR OUTLET SERVOMOTOR Remove the 2 screws and servomotor. 7. REMOVE EXPANSION VALVE (a) Pry out the packing. HINT: At the time of reassembly, please refer to the following item. Do not reuse the packing. (b) Using SST, remove the 2 bolts, then separate the expansion valve, and tube connector. SST Torque: 4.1 N m (42 kgf cm, 36 in. lbf) HINT: At the time of reassembly, please refer to the following item. Lubricate 4 new Orings with compressor oil and install them to the valve. 8. REMOVE EVAPORATOR TEMPERATURE SENSOR (a) Using a screwdriver, pull out the sensor with bracket plate. HINT: Tape the screwdriver tip before use. (b) Release the 2 claws and sensor from bracket plate. 9. REMOVE EVAPORATOR (a) Remove air mix servomotor. (1) Disconnect the connector. (2) Remove the 3 screws and servomotor. I

22 UNIT AC29 SST I02401 (b) Remove tube and accessory. (1) Pry out packing. HINT: At the time of installation, please refer to the following item. Do not reuse the packing. (2) Using SST, remove the 2 bolts and the tube and accessory. SST Torque: 4.1 N m (42 kgf cm, 36 in. lbf) NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 2 new Orings with compressor oil and install them to the tube. (3) Remove screw and drain pipe. I18093 (c) Remove evaporator. (1) Remove the screw and drain hose. (2) Remove the 4 screws and cover. (3) Pull out the evaporator. HINT: At the time of installation, please refer to the following item. If evaporator is replaced, add compressor oil to evaporator. Add 40 cc (1.4 fl.oz.) Compressor oil: NDOIL 8 or equivalent 10. REMOVE INSULATOR FROM HEATER CASE 11. REMOVE AIR DUCT 2495

23 AC30 UNIT COOL 7 6 INSPECTION AC25N02 1. INSPECT AIR MIX SERVOMOTOR (a) Inspect the air mix servomotor operation. (1) Connect the positive (+) lead from the battery to terminal 7 and negative () lead to terminal 6, then check that the arm turns to COOL side smoothly. I11038 WARM 6 (2) Connect the positive (+) lead from the battery to terminal 6 and negative () lead to terminal 7, then check that the arm turns to WARM side smoothly. If operations are not as specified, replace the servomotor. 7 I11856 (kω) (b) Inspect position sensor resistance. Measure resistance between terminals at servomotor arm each position as shown in the chart Tester connection Condition Specified condition MAX. COOL MAX. WARM I Constant kω 1 5 Max. cool kω 1 5 Max. warm kω If resistance is not as specified, replace the servomotor. 2. INSPECT EVAPORATOR (a) Check evaporator fins for blockage. If the fins are clogged, clean them with compressed air. NOTICE: Never use water to clean the evaporator. (b) Check fitting for cracks or scratches. If necessary, repair or replace. 3. INSPECT HEATER RADIATOR Inspect fins for blockage. If the fins are clogged, clean them with compressed air. 2496

24 UNIT REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC28 ). AC31 AC15Y

25 AC32 UNIT INSTALLATION Installation is in the reverse order of removal (See page AC26 ). AC15Z

26 BLOWER UNIT AC33 BLOWER UNIT COMPONENTS AC16005 Instrument Panel Air Duct (Duct Side) Bracket Blower Unit Air Inlet Servomotor Blower Unit Case Air Refiner Filter Air Refiner Flame Cover Blower Motor I

27 AC34 BLOWER UNIT REMOVAL AC25O03 1. REMOVE INSTRUMENT PANEL (See page BO139 ) 2. REMOVE AIR DUCT (DUCT SIDE) (a) Disconnect the connector and connector clamp. (b) Remove the screw. (c) Release the 2 claws and pull out the air duct. I DISCONNECT WIRE HARNESS (a) Disconnect the connector and connector clamp. I18096 (b) Remove the wire harness clamp and disconnect the connector. I REMOVE BLOWER UNIT (a) Remove the 2 bolts and bracket. (b) Remove the bolt, screw and nut. (c) Release the claw and remove the blower unit. I

28 BLOWER UNIT AC35 DISASSEMBLY 1. REMOVE AIR REFINER FILTER (a) Release the 4 claws and remove the cover. (b) Pull out the air refiner filter. 2. REMOVE AIR INLET SERVOMOTOR Remove the 3 screws and servomotor. 3. REMOVE BLOWER MOTOR Remove the 3 screws and blower motor. AC

29 AC36 BLOWER UNIT REASSEMBLY Reassembly is in the reverse order of disassembly (See page AC35 ). AC

30 BLOWER UNIT INSTALLATION Installation is in the reverse order of removal (See page AC34 ). AC37 AC

31 AC38 COMPRESSOR AND MAGNETIC CLUTCH COMPRESSOR AND MAGNETIC CLUTCH ONVEHICLE INSPECTION 1. INSPECT COMPRESSOR FOR METALLIC SOUND AC37X01 Check there is abnormal metallic sound from the compressor when the A/C switch is ON. If abnormal metallic sound is heard, replace the compressor assembly. 2. INSPECT REFRIGERANT PRESSURE (See page AC3 ) 3. INSPECT VISUALLY FOR LEAKAGE OF REFRIGER ANT Using a gas leak detector, check for leakage of refrigerant. If there is any leakage, replace the compressor assembly. 2 1 I INSPECT COMPRESSOR LOCK SENSOR RESIS TANCE (a) Disconnect the connector. (b) Measure resistance between terminals 1 and 2. Standard resistance: 990 1,210 Ω at 20 C (68 F) If resistance is not as specified, replace the compressor. 5. MAKE THESE VISUAL CHECKS: (a) Leakage of grease from the clutch bearing. (b) Signs of oil on the pressure plate or rotor. 6. INSPECT MAGNETIC CLUTCH BEARING FOR NOISE (a) Start engine. (b) Check for abnormal noise from the compressor when the A/C switch is OFF. If abnormal noise is being emitted, replace the rotor of magnetic clutch INSPECT MAGNETIC CLUTCH OPERATION (a) Disconnect the connector. (b) Connect the positive (+) lead from the battery to terminal 3 and the negative () lead to the body ground. (c) Check that the magnetic clutch is energized. If operation is not as specified, replace the magnetic clutch. I

32 COMPRESSOR AND MAGNETIC CLUTCH AC39 COMPONENTS AC0YY05 PS Pump Compressor Bracket Pump Stay 39 (400, 29) Suction Hose 10 (100, 7) 58 (590, 43) 39 (400, 29) ORing Washer PS Pump Bracket 58 (590, 43) Discharge Hose ORing 26 (265, 19) 52 (530, 38) 58 (590, 43) 52 (530, 38) 52 (530, 38) Compressor Drive Belt Compressor Pressure Plate Shim Rotor Stator 13.2 (135, 9) Snap Ring Snap Ring N m (kgf cm, ft lbf) :Specified torque Nonreusable part I

33 AC40 REMOVAL COMPRESSOR AND MAGNETIC CLUTCH AC37Y01 1. RUN ENGINE AT IDLE SPEED WITH A/C ON FOR APPROX. 10 MINUTES 2. STOP ENGINE 3. DISCONNECT NEGATIVE ( ) TERMINAL CABLE FROM BATTERY 4. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 5. REMOVE DRIVE BELT (See page AC17 ) 6. DISCONNECT DISCHARGE AND SUCTION HOSES Remove the 2 nuts and disconnect the both hoses. NOTICE: Cap the open fitting immediately to keep moisture or dirt out of the system. I REMOVE PS PUMP WITH PRESSURE FEED AND RE TURN TUBES STILL CONNECTED (a) Disconnect the PS pump connector and PS pump tube clamp. (b) Disconnect the engine wire. I14842 (c) Remove the 2 PS pump set bolts and slide the PS pump backward. I REMOVE COMPRESSOR (a) Remove the bolt and PS pump bracket. I

34 COMPRESSOR AND MAGNETIC CLUTCH AC41 (b) (c) Remove the 3 bolts and compressor bracket. Disconnect the connector. I14844 (d) (e) Remove the nut and 2 bolts. Using a torx socket (E10), remove the stud bolt and compressor. I

35 AC42 SST COMPRESSOR AND MAGNETIC CLUTCH DISASSEMBLY AC37Z01 DISASSEMBLE MAGNETIC CLUTCH (a) Remove the pressure plate. (1) Using SST and a socket wrench, remove the shaft bolt. SST AC0943 SST (2) Install SST on the pressure plate. SST AC0944 SST (3) Using SST and a socket wrench, remove the pressure plate. SST , AC0945 (4) Remove the shims from the pressure plate. Shim Pressure Plate AC0946 SST (b) Remove the rotor. (1) Remove the snap ring. AC

36 COMPRESSOR AND MAGNETIC CLUTCH AC43 (2) Using a plastic hammer, tap the rotor off the shaft. NOTICE: Be careful not to damage the pulley when tapping on the rotor. AC1743 (c) Remove the stator. (1) Disconnect the stator lead wire from the compressor. AC1744 (2) Remove the snap ring. SST AC0950 (3) Remove the stator. Stator AC

37 AC44 COMPRESSOR AND MAGNETIC CLUTCH SST REASSEMBLY 1. ASSEMBLE MAGNETIC CLUTCH (a) Install the stator. (1) Install the stator on compressor. (2) Install the new snap ring. AC38001 AC0950 RShape Snap Ring NOTICE: The snap ring should be installed so that its beveled side faces up. (3) Connect the stator lead wire to the compressor. Stator Compressor N20012 SST (b) Install the rotor. (1) Install the rotor on the compressor. (2) Install the new snap ring. AC0947 Snap Ring NOTICE: The snap ring should be installed so that its beveled side faces up. RShape Rotor Compressor N20013 Shim (c) Install the pressure plate. (1) Install the shims to the pressure plate. (2) Install the pressure plate on the rotor. Pressure Plate AC

38 COMPRESSOR AND MAGNETIC CLUTCH AC45 SST (3) Using SST and a torque wrench, install the shaft bolt. Torque: 13.2 N m (135 kgf cm, 9 ft lbf) SST AC0945 Dial Indicator N AFTER REASSEMBLY, CHECK MAGNETIC CLUTCH CLEARANCE (a) Set the dial indicator to the pressure plate of the magnetic clutch. (b) Connect the magnetic clutch lead wire to the positive (+) terminal of the battery. (c) Check the clearance between the pressure plate and rotor when connecting the negative () terminal to the battery. Standard clearance: 0.5 ± 0.15 mm (0.020 ± in.) If the clearance is not within the standard clearance, adjust the clearance using shims to obtain the standard clearance. Shim thickness: 0.1 mm (0.004 in.) 0.3 mm (0.012 in.) 0.5 mm (0.020in.) 2511

39 AC46 COMPRESSOR AND MAGNETIC CLUTCH INSTALLATION 1. INSTALL COMPRESSOR (a) Install the compressor with the stud bolt. Torque: 26 N m (265 kgf cm, 19 ft lbf) (b) Install the 2 bolts and nut. Torque: Bolt: 52 N m (530 kgf cm, 38 ft lbf) Nut: 52 N m (530 kgf cm, 38 ft lbf) (c) Connect the connector. AC38101 A B A I14844 (d) Install the compressor bracket with the 3 bolts. Torque: bolt A: 39 N m (400 kgf cm, 29 ft lbf) bolt B: 52 N m (530 kgf cm, 38 ft lbf) (e) Install the PS pump bracket with the bolt. Torque: 52 N m (530 kgf cm, 38 ft lbf) 2. INSTALL PS PUMP (a) Install 2 PS pump set bolt. Torque: 58 N m (590 kgf cm, 43 ft lbf) (b) Connect the engine wire. (c) Connect the PS pump connector and wire harness clamp. 3. CONNECT DISCHARGE AND SUCTION HOSES Connect the both hoses with 2 nut. Torque: 10 N m (100 kgf cm, 7 ft lbf) NOTICE: Hose should be connected immediately after the caps have been removed. HINT: Lubricate 2 new Orings with compressor oil and install them to the hoses. 4. INSTALL DRIVE BELT (See page AC18 ) 5. INSPECT DRIVE BELT TENSION (See page AC16 ) 6. CONNECT NEGATIVE () TERMINAL CABLE TO BAT TERY 7. EVACUATE AIR FROM REFRIGERATION SYSTEM AND CHARGE SYSTEM WITH REFRIGERANT Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 8. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. 9. INSPECT A/C OPERATION 2512

40 CONDENSER CONDENSER ONVEHICLE INSPECTION 1. INSPECT CONDENSER FINS FOR BLOCKAGE OR DAMAGE If the fins are clogged, wash them with water and dry with compressed air. NOTICE: Be careful not to damage the fins. If the fins are bent, straighten them with a screwdriver or pliers. 2. INSPECT CONDENSER AND FITTINGS FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. If there is leakage, check the tightening torque at the joints. AC47 AC16B

41 AC48 CONDENSER COMPONENTS AC25R03 Condenser Air Cleaner Assembly Liquid Tube 10 (100, 7) ORing Discharge Hose ORing Radiator Upper Support 10 (100, 7) Air Cleaner Inlet Bracket Condenser Dryer Filter Cap 12.3 (125, 9) N m (kgf cm, ft lbf) : Specified torque Nonreusable part Compressor oil NDOIL 8 or equivalent I

42 REMOVAL CONDENSER AC49 AC DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount : 600 ± 50 g (21.16 ± 1.76 oz.) 2. REMOVE AIR CLEANER DUCT AND AIR CLEANER ASSEMBLY 3. REMOVE ECU OUTLET DUCT 4. REMOVE 2 RADIATOR UPPER SUPPORTS Remove the 2 bolts and upper supports. I11047 I DISCONNECT DISCHARGE HOSE AND LIQUID TUBE Remove the 2 bolts and disconnect the hose and tube. Torque: 10 N m (100 kgf cm, 7 ft lbf) NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 2 new Orings with compressor oil and install them to the hose and tube. 6. REMOVE CONDENSER (a) Remove the 4 bolts and 2 brackets. (b) Push the radiator toward engine. (c) Push the condenser toward radiator and pull it upward. HINT: At the time of installation, please refer to the following item. If condenser is replaced, add compressor oil to the condenser. Add 40 cc (1.4 fl. oz) Compressor oil: ND OIL 8 or equivalent 2515

43 AC50 10 mm (0.39 in.) Hexagon Wrench Modulator CONDENSER I10090 REPLACEMENT AC22C07 REPLACE DRYER FROM MODULATOR (a) Using a hexagon wrench (10 mm, 0.39 in.), remove the cap from the modulator. (b) Remove the filter from the modulator. (c) Using pliers, remove the dryer. I Layered Part (d) Insert a new dryer into the modulator. NOTICE: Do not remove the dryer from a vinyl bag until inserting it into the modulator. Install the dryer with its 2 layered part faced upward to the modulator. I10093 Protrusion (e) Insert the filter into the modulator. NOTICE: Install the filter with its protrusion faced downward to the modulator. I10091 (f) Install the cap to the modulator. (1) Apply compressor oil to the Orings and screw part of the cap. Compressor oil: NDOIL 8 or equivalent (2) Using a hexagon wrench (10 mm, 0.39 in.), install the caps. Torque: 12.3 N m (125 kgf cm, 9 ft lbf) I

44 CONDENSER INSTALLATION Installation is in the reverse order of removal (See page AC49 ). AC51 AC16D

45 AC52 EXPANSION VALVE EXPANSION VALVE ONVEHICLE INSPECTION 1. CHECK QUANTITY OF GAS DURING REFRIGERATION CYCLE 2. SET ON MANIFOLD GAUGE SET (See page AC19 ) 3. RUN ENGINE Run the engine at 1,500 rpm for at least 5 minutes. Then check that the high pressure reading is MPa (14 16 kgf/cm 2, psi). 4. CHECK EXPANSION VALVE If the expansion valve is faulty, the low pressure reading will drop to 0 kpa (0 kgf/cm 2, 0 psi). AC16K

46 I02404 REMOVAL EXPANSION VALVE AC53 AC DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 2. REMOVE INSTRUMENT PANEL (See page BO139 ) 3. REMOVE EXPANSION VALVE (a) Pry out the packings. HINT: At the time of installation, please refer to the following item. Do not reuse the packing. (b) Using SST, remove the 4 bolts and separate the expansion valve and tube and accessory. SST Torque: 4.1 N m (42 kgf cm, 36 in. lbf) NOTICE: Cap the open fittings immediately to keep moisture or dirt out of the system. HINT: At the time of installation, please refer to the following item. Lubricate 6 new Orings with compressor oil and install them to the tube and valve. 2519

47 AC54 EXPANSION VALVE INSTALLATION Installation is in the reverse order of removal (See page AC53 ). AC16M

48 BLOWER MOTOR BLOWER MOTOR INSPECTION AC55 AC20I03 1. REMOVE BLOWER MOTOR (a) Remove the wire harness clamp and disconnect the connector. (b) Remove the 3 screws and blower motor. I INSPECT BLOWER MOTOR OPERATION Connect the positive (+) lead from the battery to terminal 2 and negative () lead to terminal 1, then check that the motor operations smoothly. If operation is not as specified, replace the blower motor. I INSTALL BLOWER MOTOR (a) Install the blower motor with the 3 screws. (b) Connect the connector and wire harness clamp. I

49 AC56 BLOWER MOTOR CONTROL RELAY BLOWER MOTOR CONTROL RELAY INSPECTION 1. REMOVE GLOVE COMPARTMENT DOOR (See page BO139 ) AC25T02 2. REMOVE BLOWER MOTOR CONTROL RELAY (a) Disconnect the connectors. (b) Remove the screw and blower motor control relay. I18098 M+ M +B SI GND 3. INSPECT BLOWER MOTOR CONTROL CIRCUIT Inspect the wire harness side connector from the back side, as shown in the chart. Test conditions: Turn ignition switch to ON Operate blower motor (High blower speed) I05291 Terminals GND Body Ground Standard Value Continuity +B Body Ground Battery positive voltage +M Body Ground Battery positive voltage M+ M Battery positive voltage SI Body Ground 1 3 V If resistance is not as specified, replace the blower motor control relay. 4. INSTALL BLOWER MOTOR CONTROL RELAY (a) Install the blower motor control relay with the screw. (b) Connect the connectors. 5. INSTALL GLOVE COMPARTMENT DOOR (See page BO149 ) I

50 AIR INLET SERVOMOTOR AIR INLET SERVOMOTOR INSPECTION 1. REMOVE GLOVE COMPARTMENT DOOR (See page BO139 ) AC57 AC REMOVE BRACKET (a) Disconnect the wire harness clamp. (b) Remove the 2 bolts and bracket. I REMOVE AIR INLET SERVOMOTOR (a) Disconnect the connector. (b) Remove the 3 screws and servomotor. I03730 FRESH 6 4. INSPECT AIR INLET SERVOMOTOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 7 and negative () lead to terminal 6, then check that the arm turns to FRESH side smoothly. 7 I (b) Connect the positive (+) lead from the battery to terminal 6 and negative () lead to terminal 7, then check that the arm turns to RECIRC side smoothly. If operations are not as specified, replace the servomotor. 7 RECIRC I

51 AC58 AIR INLET SERVOMOTOR (kω) 5. INSPECT POSITION SENSOR RESISTANCE Measure resistance between terminals at servomotor arm each position as shown in the chart Tester connection Condition Specified condition REC FRS I Constant kω 3 5 REC kω 3 5 FRS kω If resistance is not as specified, replace the servomotor. 6. INSTALL AIR INLET SERVOMOTOR (a) Install the servomotor with the 3 screws. (b) Connect the connector. I INSTALL BRACKET (a) Install the bracket with 2 bolts. (b) Connect the wire harness clamp. 8. INSTALL GLOVE COMPARTMENT DOOR (See page BO149 ) I

52 AIR OUTLET SERVOMOTOR AIR OUTLET SERVOMOTOR INSPECTION AC59 AC25W02 1. REMOVE INSTRUMENT PANEL (See page BO139 ) 2. REMOVE AIR DUCT (a) Disconnect the connector clamp. (b) Remove the 3 screws and air duct. I REMOVE AIR OUTLET SERVOMOTOR (a) Disconnect the connector. (b) Remove the 2 screws and servomotor. I18100 FACE 6 4. INSPECT AIR OUTLET SERVOMOTOR OPERATION (a) Connect the positive (+) lead from the battery to terminal 7 and negative () lead to terminal 6, then check that the arm turns to FACE side smoothly. 7 I (b) Connect the positive (+) lead from the battery to terminal 6 and negative () lead to terminal 7, then check that the arm turns to DEF side smoothly. If operations are not as specified, replace the servomotor. 7 DEF I

53 AC60 AIR OUTLET SERVOMOTOR (kω) 5. INSPECT POSITION SENSOR RESISTANCE Measure resistance between terminals at servomotor arm each position as shown in the chart Tester connection Condition Specified condition FACE DEF I Constant kω 3 5 FACE kω 3 5 DEF kω If resistance is not as specified, replace the servomotor. 6. INSTALL AIR OUTLET SERVOMOTOR (a) Install the servomotor with the 2 screws. (b) Connect the connector. I INSTALL AIR DUCT (a) Install the air duct with the 3 screws. (b) Connect the connector clamp. 8. INSTALL INSTRUMENT PANEL (See page BO149 ) I

54 SOLAR SENSOR SOLAR SENSOR INSPECTION 1. REMOVE SOLAR SENSOR AC61 AC25X02 Using a screwdriver, pull out the sensor, then disconnect the connector. HINT: Tape the screwdriver tip before use. I INSPECT SOLAR SENSOR CONTINUITY (a) Cover the sensor with a cloth, check that the no continuity exists between terminals. If continuity exists, replace the sensor. N (b) Remove the cloth from the sensor and subject the sensor to electric light, check that continuity exists between terminals. If no continuity exists, replace the sensor. N INSTALL SOLAR SENSOR Connect the connector and install the solar sensor. I

55 AC62 ROOM TEMPERATURE SENSOR ROOM TEMPERATURE SENSOR AC20Q04 INSPECTION 1. REMOVE LOWER FINISH PANEL (a) Remove the 3 screws. (b) Release the 3 claws and pull out the lower finish panel. 2. REMOVE ROOM TEMPERATURE SENSOR (a) Disconnect the connector and aspirator hose. (b) Release the 2 claws and pull out the sensor. I INSPECT ROOM TEMPERATURE SENSOR RESIS TANCE Measure resistance between terminals at each temperature as shown in the chart. N12649 Temperature Specified condition 25 C (77 F) kω 50 C (122 F) kω If resistance is not as specified, replace the sensor. 4. INSTALL ROOM TEMPERATURE SENSOR (a) Install the sensor and fit the 2 claws. (b) Connect the aspirator hose and connector. 5. INSTALL LOWER FINISH PANEL (a) Install the lower finish panel and fit the 3 claws. (b) Install the 3 screws. I

56 I11054 AMBIENT TEMPERATURE SENSOR AMBIENT TEMPERATURE SENSOR INSPECTION AC63 AC20R03 1. REMOVE AMBIENT TEMPERATURE SENSOR (a) Disconnect the connector. (b) Using a clip remover, pull out the sensor from bumper reinforcement. 2. INSPECT AMBIENT TEMPERATURE SENSOR RESIS TANCE Measure resistance between terminals at each temperature as shown in the chart. I11055 Temperature Specified condition 25 C (77 F) kω 50 C (122 F) kω If resistance is not as specified, replace the sensor. 3. INSTALL AMBIENT TEMPERATURE SENSOR (a) Push the sensor in bumper reinforcement. (b) Connect the connector. I

57 AC64 EVAPORATOR TEMPERATURE SENSOR EVAPORATOR TEMPERATURE SENSOR INSPECTION AC25Y02 1. REMOVE LOWER FINISH PANEL (See page BO139 ) 2. REMOVE EVAPORATOR TEMPERATURE SENSOR (a) Disconnect the connector. (b) Using a screwdriver, pull out the sensor with bracket plate. HINT: Tape the screwdriver tip before use. I18102 (c) Release the 2 claws and remove the sensor from bracket plate. I03738 Thermometer Ice 10 cm (3.94 in.) Ohmmeter 3. INSPECT EVAPORATOR TEMPERATURE SENSOR RESISTANCE (a) Place the sensor in cold water, and while changing the temperature of the water, measure resistance at the connector and at the same time, measure temperature of the water with a thermometer. Sensor AC0175 (Ω) 5,000 4,500 4,000 3,500 3,000 2,500 2,000 1,500 1, ( C) ( F) Z04352 (b) Compare the 2 readings on the chart. If resistance value is not as specified, replace the sensor. 2530

58 EVAPORATOR TEMPERATURE SENSOR AC65 4. INSTALL EVAPORATOR TEMPERATURE SENSOR (a) Install the sensor in bracket plate and 2 claws. I03738 (b) Push in the sensor with the bracket plate. (c) Connect the connector. 5. INSTALL LOWER FINISH PANEL (See page BO149 ) I

59 AC66 PRESSURE SWITCH PRESSURE SWITCH ONVEHICLE INSPECTION AC16Z04 1. SET ON MANIFOLD GAUGE SET (See page AC19 ) 2. DISCONNECT CONNECTOR FROM PRESSURE SWITCH 3. RUN ENGINE AT APPROX. 1,500 RPM I11043 Magnetic Clutch Control Low Pressure Side ON (Continuity) 196 kpa 22.5 kpa (2.0 kgf/cm 2, (2.3 kgf/cm 2, 33 psi) 28 psi) OFF (No Continuity) High Pressure Side ON (Continuity) 3,140 kpa 2,550 kpa (26 kgf/cm 2, (32.0/kgf cm 2, 370 psi) 455 psi) OFF (No Continuity) I Magnetic clutch control: INSPECT PRESSURE SWITCH OPERATION (a) Connect the positive (+) lead from the ohmmeter to terminal 4 and the negative () lead to terminal 1. (b) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. Cooling Fan Control ON (Continuity) OFF (No Continuity) 1,520 kpa (15.5/kgf/cm 2, 220 psi) 1,230 kpa (12.5 kgf/cm 2, 178 psi) I Cooling fan control: INSPECT PRESSURE SWITCH OPERATION (a) Connect the positive (+) lead from the ohmmeter to terminal 2 and the negative () lead to terminal 3. (b) Check continuity between terminals when refrigerant pressure is changed, as shown in the illustration. If operation is not as specified, replace the pressure switch. 6. STOP ENGINE AND SET OFF MANIFOLD GAUGE SET 7. CONNECT CONNECTOR TO PRESSURE SWITCH 2532

60 REMOVAL PRESSURE SWITCH AC67 AC DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM HINT: At the time of installation, please refer to the following item. Evacuate air from refrigeration system. Charge system with refrigerant and inspect for leakage of refrigerant. Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 2. REMOVE RADIATOR GRILLE (See page BO4 ) I REMOVE PRESSURE SWITCH FROM LIQUID TUBE Disconnect the connector and remove the pressure switch. Torque: 10 N m (100 kgf cm, 7 ft lbf) HINT: Lock the switch mount on the tube with an open end wrench, being careful not to deform the tube, and remove the switch. At the time of installation, please refer to the following item. Lubricate a new Oring with compressor oil and install the switch. 2533

61 AC68 PRESSURE SWITCH INSTALLATION Installation is in the reverse order of removal (See page AC67 ). AC

62 HEATER MAIN RELAY HEATER MAIN RELAY INSPECTION 1. REMOVE FRONT DOOR SCUFF PLATE LH (See page BO139 ) 2. REMOVE COWL SIDE TRIM BOARD LH (See page BO139 ) AC69 AC25Z02 3. REMOVE HEATER MAIN RELAY (a) Disconnect the connectors. (b) Remove the 2 passenger side junction block set nuts. I11752 (c) Remove the heater main relay from passenger side junction block. Heater Main Relay I INSPECT HEATER MAIN RELAY CONTINUITY Condition Tester connection Specified condition Constant Continuity Z19533 Apply B+ between terminals 1 and Continuity If continuity is not as specified, replace the relay. 5. INSTALL HEATER MAIN RELAY (a) Install the heater main relay to passenger side junction block. (b) Install the passenger side junction block set nuts. (c) Connect the connectors. 6. INSTALL COWL SIDE TRIM BOARD LH (See page BO149 ) 7. INSTALL FRONT DOOR SCUFF PLATE LH (See page BO149 ) 2535

63 AC70 Magnetic Clutch Relay MAGNETIC CLUTCH RELAY MAGNETIC CLUTCH RELAY INSPECTION AC20U05 1. REMOVE MAGNETIC CLUTCH RELAY FROM RELAY BLOCK NO.3 I I INSPECT MAGNETIC CLUTCH RELAY (Marking: A.C COMP) CONTINUITY Condition Tester connection Specified condition Constant 1 2 Continuity Apply B+ between terminals 1 and Continuity If continuity is not as specified, replace the relay. 2536

64 No. 2 Cooling Fan Relay COOLING FAN RELAY COOLING FAN RELAY INSPECTION AC71 AC REMOVE NO.2 COOLING FAN RELAY FROM RELAY BLOCK NO.3 I11740 No. 3 Cooling Fan Relay 2. REMOVE NO.3 COOLING FAN RELAY FROM RELAY BLOCK NO.3 I INSPECT NO.2 COOLING FAN RELAY (Marking: FAN NO.2) CONTINUITY Condition Tester connection Specified condition 2 Constant Continuity 1 4 N23635 Apply B+ between terminals 1 and Continuity If continuity is not as specified, replace the relay. 4. INSPECT NO.3 COOLING FAN RELAY (Marking: FAN NO.3) CONTINUITY Check the relay in the same way as for MAGNETIC CLUTCH RELAY. 2537

65 AC72 CONDENSER FAN CONDENSER FAN ONVEHICLE INSPECTION 1. INSPECT CONDENSER FAN OPERATION Inspect the fan operation, as shown in the chart below. AC17303 Test conditions: Ignition switch ON Blower speed control switch position HI Temperature control dial at MAX. COOL position Install manifold gauge set A/C switch ON Condition Engine coolant temperature 91 C (196 F) or below Engine coolant temperature 100 C (212 F) or above Refrigerant pressure is less than 1,520 kpa (15.5 kgf cm 2, 220 psi) Fan operation (Fan speed) Rotate (Low speed) Rotate (High speed) Rotate (Low speed) Refrigerant pressure is 1,520 kpa (15.5 kgf cm 2 Rotate (High speed), 220 psi) or above If operation is not as specified, proceed to the next inspection. (+) () B INSPECT CONDENSER FAN MOTOR OPERATION (a) Disconnect the fan connector. (b) Connect battery and ammeter. (c) Check that the fan rotates smoothly, and then check the reading on the ammeter. Specified amperage: A ar 20 C (68 F) If operation is not as specified, replace the fan motor. If operation is as specified, check the pressure switch, cooling fan relays and engine coolant temp. switch. 2538

66 CONDENSER FAN AC73 COMPONENTS AC38601 Air Cleaner Inlet Upper Radiator Hose Air Cleaner and MAF Meter Assembly MAF Meter Connector Cooling Fan Assembly Cooling Fan Connector Radiator Reservoir Hose x 6 5 (50, 44 in. lbf) ECM Outlet Duct N m (kgf cm, ft lbf) : Specified torque B

67 AC74 CONDENSER FAN No.2 Fan Motor No.1 Fan Motor No.2 Fan Connector Holder No.1 Fan Fan Shroud Assembly B

68 CONDENSER FAN AC75 AC38701 REMOVAL 1. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all coolant. 2. REMOVE AIR CLEANER INLET 3. REMOVE AIR CLEANER AND MAF METER AS SEMBLY 4. REMOVE COOLING FAN (a) Disconnect the upper radiator hose from the radiator. (b) Disconnect the ECM outlet duct from the ECM box. (c) Disconnect the wire for cooling fan from the clamp on the cooling fan. (d) Disconnect the 2 cooling fan connector. (e) Disconnect the radiator reservoir hose from the radiator. (f) Remove the 6 bolts and cooling fan. B

69 AC76 CONDENSER FAN DISASSEMBLY 1. REMOVE FANS (a) Remove the nut and fan. (b) Remove the 2 fans. AC38801 B REMOVE FAN MOTORS (a) Disconnect the wires and connector holders from the fan shroud. (b) Remove the 3 screws and fan motor. (c) Remove the 2 fan motors. B

70 CONDENSER FAN REASSEMBLY AC77 AC INSTALL FAN MOTORS (a) Install the fan motor with the 3 screws. Install the 2 fan motors. B00921 (b) Install the wires and connector holders to the fan shroud as shown in the illustration. B INSTALL FANS Install the fan with the nut. Install the 2 fans. B

71 AC78 B02071 CONDENSER FAN INSTALLATION AC38A01 1. INSTALL COOLING FAN (a) Install the cooling fan with the 6 bolts. Torque: 5.0 N m (50 kgf cm, 44 in. lbf) (b) Connect the upper radiator hose to the radiator. (c) Connect the ECM outlet duct to the ECM box. (d) Connect the wire for cooling fan to clamp on the cooling fan. (e) Connect the 2 cooling fan connectors. (f) Connect the radiator reservoir hose to the radiator. 2. INSTALL AIR CLEANER AND MAF METER AS SEMBLY 3. INSTALL AIR CLEANER INLET 4. FILL WITH ENGINE COOLANT 5. START ENGINE AND CHECK FOR COOLANT LEAKS 2544

72 Wire harness side: Connector B CONTROL ASSEMBLY CONTROL ASSEMBLY ONVEHICLE INSPECTION 1. REMOVE A/C CONTROL ASSEMBLY (See page AC84 ) Connector A AC79 AC INSPECT A/C CONTROL ASSEMBLY CIRCUIT (a) Disconnect the connector from the A/C control assembly and inspect the connector on the wire harness side, as shown in the chart below. Test condition: Turn ignition switch ON Connector B Connector A I09813 A13 A6 Tester connection Condition Specified condition Cover solar sensor with a cloth Solar sensor subject to electric light No continuity Continuity B14 Ground Constant Continuity A17 A18 Cabin temperature at 25 C (77 F) Approx. 1.7 kω A5 A18 Evaporator temperature at 25 C (77 F) Approx. 1.5 kω B4 Ground Turn ignition switch to ACC Battery positive voltage B13 Ground Turn ignition switch to ON Turn ignition switch to LOCK or ACC Battery positive voltage No voltage B12 Ground Turn light control switch to TAIL Battery positive voltage B5 Ground Constant Battery positive voltage If the circuit is not as specified, inspect the circuit connected to other parts. If the circuit is as specified, proceed to INSPECTION on page AC

73 AC80 CONTROL ASSEMBLY From back side: (b) Connector B Connect the connector to amplifier and inspect the wire harness side connector from the back side, as shown in the chart. Test conditions: Running engine at idle speed Blower speed control dial at HI position Temperature control dial at MAX. COOL position A/C switch ON Connector A I07266 Tester connection Condition Specified condition A18 Ground Constant Continuity Hazard switch: OFF No continuity A1 Ground Hazard switch: ON Continuity R/F switch: FRESH Battery positive voltage A2 Ground R/F switch: RECIRC Below 1.0 V Mode control dial: FACE Below 1.0 V A3 Ground Mode control dial: DEF Battery positive voltage Temperature control dial: MAX COOL Below 1.0 V A4 Ground Temperature control dial: MAX HOT Battery positive voltage A6 A18 Constant 5.0 ± 0.5 V R/F switch: FRESH Below 1.0 V A9 Ground R/F switch: RECIRC Battery positive voltage Mode control dial: DEF Below 1.0 V A10 Ground Mode control dial: FACE Battery positive voltage Temperature control dial: MAX HOT Below 1.0 V A11 Ground Temperature control dial: MAX COOL Battery positive voltage Temperature control dial: MAX HOT Approx. 1.0 V A14 A18 Temperature control dial: MAX COOL Approx. 4.0 V Mode control dial: DEF Approx. 1.0 V A15 A18 Mode control dial: FACE Approx. 4.0 V R/F switch: FRESH Approx. 1.0 V A16 A18 R/F switch: RECIRC Approx. 4.0 V Parking drake lever: Release Battery positive voltage B2 Ground Parking drake lever: Operate Below 1.0 V Pattern select switch: Except PWR Battery positive voltage B3 Ground Pattern select switch: PWR Below 1.0 V 2546

74 CONTROL ASSEMBLY AC81 B6 Ground B7 Ground B8 Ground Ignition switch: ON Ignition switch: OFF Blower motor: ON Blower motor: OFF Pattern select switch: Except SNOW Pattern select switch: SNOW Below 1.0 V Battery positive voltage Pulse generation Approx. 5.0 V Battery positive voltage Below 1.0 V B10 Ground Passenger seat belt: unfastened Passenger seat belt: fasted Below 1.0 V Battery positive voltage If the circuit is not as specified, proceed to INSPECTION on page AC INSTALL A/C CONTROL ASSEMBLY (See page AC91 ) 2547

75 AC82 CONTROL ASSEMBLY COMPONENTS AC26202 w/ LEXUS Navigation System: Center Register Cover Center Cluster Finish Panel Center Cluster Finish Panel Brackets A/C Control Assembly Brackets Radio Assembly Lower Center Cluster Finish Panel I

76 CONTROL ASSEMBLY AC83 A/C Amplifier Bulbs Bulbs P/C Board Knob Sets Lens Dial Knobs Panel I

77 AC84 CONTROL ASSEMBLY AC26302 REMOVAL 1. REMOVE CENTER CLUSTER FINISH PANEL (See page BO139 ) 2. REMOVE LOWER CENTER CLUSTER FINISH PANEL (See page BO139 ) 3. REMOVE A/C CONTROL ASSEMBLY (a) Remove the 4 bolts and pull out the A/C control assembly with radio assembly, then disconnect the connectors. I18104 (b) (c) Remove the 12 screws and 2 brackets. Separate the A/C control assembly and radio assembly. I

78 CONTROL ASSEMBLY DISASSEMBLY 1. REMOVE A/C AMPLIFIER (a) Remove the 4 screws. AC85 AC26402 I11763 (b) Using a screwdriver, release the 4 claws and pull out the A/C amplifier. HINT: Tape the screwdriver tip before use. I11777 Flat Harness (c) Release the connector lock and pull out the flat harness. NOTICE: Pull the lock of the connector securely toward you and pull off the flexible flat cable. Connector Lock I REMOVE BULBS Using a screwdriver, turn the bulbs to the left and pull out the bulbs. I REMOVE P/C BOARD Remove the 4 screws and P/C board. I

79 AC86 CONTROL ASSEMBLY Jumper lead I18272 NOTICE: Do not let any oil, dirt or foreign object on the connecting part of the P/C board. When holding the P/C board by hand, hold it at the edge and do not touch the soldered part and connecting part. Do not apply unnecessary force to the jumper lead. Do not let the accumulated static electricity in an operator apply to the electronic components. Do not tumble the LED as this soldered to the P/C board at right angles. 4. REMOVE DIAL KNOBS Remove the 6 screws and dial knobs. I18273 Contact NOTICE: Do not let any oil, dirt or foreign object attach on the connecting part of the connector. Do not deform the contact. Be careful not to drop the contact. I REMOVE KNOB SETS Pull out the knob sets. I

80 CONTROL ASSEMBLY AC87 Rubber Contact NOTICE: Do not let any oil, dirt or foreign object attach on the rubber contact part. I REMOVE LENS I

81 AC88 CONTROL ASSEMBLY AC26503 INSPECTION 1. INSPECT INDICTOR OPERATION Connect the positive (+) lead from the battery to terminal 4 and negative () lead to each terminal, then check that the indicator lights up as shown in the chart. Switch Tester connection DEF 13 FRESH 12 RECIRC 11 A/C 10 If operation is not as specified, replace the P/C board I INSPECT INDICATOR DIMMING OPERATION (a) Perform each indicator light up (See step 1). (b) Connect the positive (+) lead from the battery to terminal 1 and check that the each indicator dims. If the operation is not as specified, replace the P/C board. If the operation is as specified, replace the A/C amplifier. 3. INSPECT BULB OPERATION Apply the tester as shown in the illustration to the test for continuity. If continuity exists, replace the P/C board. If on continuity exists, replace the bulb. I